US2013302600A1PendingUtilityA1

Dry-in-place corrosion-resistant coating for zinc or zinc-alloy coated substrates

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Assignee: ECO GREEN COATINGS L L CPriority: Nov 28, 2011Filed: Jul 19, 2013Published: Nov 14, 2013
Est. expiryNov 28, 2031(~5.3 yrs left)· nominal 20-yr term from priority
Inventors:William D. KrippesTheodore JaroszMike SerafiniWilliam Capizzano
Y10T428/273C23C 2222/10C23C 22/33C09D 5/08Y10T428/12535C23C 22/12
41
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Claims

Abstract

A process for making a corrosion-resistant metal component. The process having the steps of: combining water, at least one zinc phosphate compound and at least one chromium compound, being chromium (III) or chromium (IV) compounds, to form a first solution; separately combining at least one silicate compound with water to form a second solution; combining the first solution with the second solution such as to form a mixed aqueous solution; optionally combining the mixed aqueous solution with at least one acrylic resin to form a coating mixture; and, applying the coating mixture to a metal substrate having a zinc or zinc-alloy surface to form a coating on the metal substrate, the coating providing chemical resistance for at least 150 hours in accordance with ASTM B117 standards where the zinc or zinc-alloy coating of the metal substrate has a weight of 0.04 oz/ft 2 (12.20 g/m 2 ).

Claims

exact text as granted — not AI-modified
What is claimed: 
     
         1 . A process for making a corrosion-resistant metal component comprising the steps of:
 combining water, at least one zinc phosphate compound and at least one chromium compound to form a first solution;   separately combining at least one silicate compound with water to form a second solution;   combining the first solution with the second solution such as to form a mixed aqueous solution;   combining the mixed aqueous solution with at least one acrylic resin to form a coating mixture; and,   applying the coating mixture to a metal substrate having a zinc or zinc-alloy surface to form a coating on the metal substrate, the coating providing chemical resistance for at least 150 hours in accordance with ASTM B117 standards where the zinc or zinc-alloy coating of the metal substrate has a weight of 0.04 oz/ft 2  (12.20 g/m 2 ).   
     
     
         2 . A process for making a corrosion-resistant metal component comprising the steps of:
 combining water, at least one zinc phosphate compound and at least one chromium compound to form a first solution;   separately combining at least one silicate compound with water to form a second solution;   combining the first solution with the second solution such as to form a coating mixture; and,   applying the coating mixture to a metal substrate having a zinc or zinc-alloy surface to form a coating on the metal substrate, the coating providing chemical resistance for at least 150 hours in accordance with ASTM B117 standards where the zinc or zinc-alloy coating of the metal substrate has a weight of 0.04 oz/ft 2  (12.20 g/m 2 ).   
     
     
         3 . A process for making a corrosion-resistant metal component coating comprising the steps of:
 combining water, at least one zinc phosphate compound and at least one chromium compound to form a first solution;   separately combining at least one silicate compound with water to form a second solution;   combining the first solution with the second solution to form a mixed aqueous solution; and,   combining the mixed aqueous solution with at least one acrylic resin to form a corrosion-resistant metal component coating mixture for applying to a metal substrate having a zinc or zinc-alloy surface to form a coating on the metal substrate, the coating providing chemical resistance for at least 150 hours in accordance with ASTM B117 standards where the zinc or zinc-alloy coating of the metal substrate has a weight of 0.04 oz/ft 2  (12.20 g/m 2 ).   
     
     
         4 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3  wherein the first solution comprises:
 not less than 4 and not more than 27 percent by weight of water; 
 not less than 5 and not more than 27 percent by weight of the at least one zinc phosphate compound; and 
 not less than 5 and not more than 27 percent by weight of chromium compound. 
 
     
     
         5 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3 , wherein the corrosion-resistant metal component coating comprises:
 not less than 20 and not more than 95 percent by weight of the first solution;   not less than 5 and not more than 12 percent by weight of the second solution;   not less than 5 and not more than 30 percent by weight of acrylic resin; and   not less than 5 and not more than 50 percent by weight of water.   
     
     
         6 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3  wherein the at least one silicate compound comprises potassium silicate. 
     
     
         7 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3  wherein the at least one acrylic resin has a pH value of no greater than 3.5. 
     
     
         8 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3  wherein the corrosion-resistant metal component coating has a pH value of no less than 1.0 and no greater than 2.5. 
     
     
         9 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3  wherein the at least one chromium compound comprises a trivalent chromium compound. 
     
     
         10 . A process for making a corrosion-resistant metal component coating as claimed in  claim 9  wherein the trivalent chromium compound is selected from the group consisting of chromium chloride hydrate, chromium (III) potassium sulfate, chromium hydroxide, chromium (III) fluoride, chromium (III) sulfate, chromium (III) sulfide, chromium (III) oxide, chromium (III) 2-ethylhexanoate, chromium (III) nitride, chromium tricarbonyl and mixtures thereof. 
     
     
         11 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3  wherein the at least one chromium compound comprises a hexavalent chromium compound. 
     
     
         12 . A process for making a corrosion-resistant metal component coating as claimed in  claim 11  wherein the hexavalent chromium compound is selected from the group consisting of chromium (VI) halides, hexafluoride, chromyl chloride, sodium chromate, chromium (VI) peroxide, sodium chromate, chromium (VI) oxide, dichromate, potassium chromate, calcium chromate, barium chromate, chromium (VI) oxide peroxide, and mixtures thereof. 
     
     
         13 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3  wherein the corrosion-resistant metal component coating is electrically conductive. 
     
     
         14 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3  wherein the corrosion-resistant metal component coating is water-repellant. 
     
     
         15 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3  wherein the corrosion-resistant metal component coating provides an enhanced surface for a zinc or zinc-alloy coated metal component for adhesion to paints. 
     
     
         16 . A process for making a corrosion-resistant metal component coating as claimed in  claim 3  wherein the corrosion-resistant metal component coating is self-healing. 
     
     
         17 . A process for making a corrosion-resistant metal component coating comprising the steps of:
 combining water, at least one zinc phosphate compound and at least one chromium compound to form a first solution;   separately combining at least one silicate compound with water to form a second solution; and   combining the first solution with the second solution to form a corrosion-resistant metal component coating mixture for applying to a metal substrate having a zinc or zinc-alloy surface to form a coating on the metal substrate, the coating providing chemical resistance for at least 150 hours in accordance with ASTM B117 standards where the zinc or zinc-alloy coating of the metal substrate has a weight of 0.04 oz/ft 2  (12.20 g/m 2 ).   
     
     
         18 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17  wherein the first solution comprises:
 not less than 4 and not more than 27 percent by weight of water; 
 not less than 5 and not more than 27 percent by weight of the at least one zinc phosphate compound; and 
 not less than 5 and not more than 27 percent by weight of chromium compound. 
 
     
     
         19 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17 , wherein the corrosion-resistant metal component coating comprises:
 not less than 20 and not more than 95 percent by weight of the first solution;   not less than 5 and not more than 12 percent by weight of the second solution; and   not less than 5 and not more than 50 percent by weight of water.   
     
     
         20 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17  wherein the at least one silicate compound comprises potassium silicate. 
     
     
         21 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17  wherein the corrosion-resistant metal component coating has a pH value of no greater than 3.5. 
     
     
         22 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17  wherein the corrosion-resistant metal component coating has a pH value of not less than 1.0 and no greater than 2.5. 
     
     
         23 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17  wherein the at least one chromium compound comprises a trivalent chromium compound. 
     
     
         24 . A process for making a corrosion-resistant metal component coating as claimed in  claim 23  wherein the trivalent chromium compound is selected from the group consisting of chromium chloride hydrate, chromium (III) potassium sulfate, chromium hydroxide, chromium (III) fluoride, chromium (III) sulfate, chromium (III) sulfide, chromium (III) oxide, chromium (III) 2-ethylhexanoate, chromium (III) nitride, chromium tricarbonyl and mixtures thereof. 
     
     
         25 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17  wherein the at least one chromium compound comprises a hexavalent chromium compound. 
     
     
         26 . A process for making a corrosion-resistant metal component coating as claimed in  claim 25  wherein the hexavalent chromium compound is selected from the group consisting of chromium (VI) halides, hexafluoride, chromyl chloride, sodium chromate, chromium (VI) peroxide, sodium chromate, chromium (VI) oxide, dichromate, potassium chromate, calcium chromate, barium chromate, chromium (VI) oxide peroxide, and mixtures thereof. 
     
     
         27 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17  wherein the corrosion-resistant metal component coating is electrically conductive. 
     
     
         28 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17  wherein the corrosion-resistant metal component coating is water-repellant. 
     
     
         29 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17  wherein the corrosion-resistant metal component coating provides an enhanced surface for a zinc or zinc-alloy coated metal component for adhesion to paints. 
     
     
         30 . A process for making a corrosion-resistant metal component coating as claimed in  claim 17  wherein the corrosion-resistant metal component coating is self-healing.

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